16/10/2003 Piaggio Ltd. Piaggio Ltd. TYPHOON 80 - 125 FUEL SYSTEM Pump driven by crank case depression Pump One way valve Auxiliary tank vent Balance pipe Front tank Main tank Vacuum tap Supply to carburettor Vent control valve Vent to atmosphere Typhoon 80 and 125 have an auxiliary fuel tank located under the front panel. The plumbing for this fuel system looks complicated. The Typhoon parts catalogue contains a illustration which should help you locate the components on the vehicle. The diagram above is intended to help explain the operation of the system and should prove useful when fault finding. VENT TO ATMOSPHERE The system has only one vent which you will find exiting under the rear mudguard. VENT CONTROL VALVE Controls venting to prevent loss of fuel from full tank. Air can enter the tank without restriction but a slight pressure is required before vapour can exit. AUX TANK VENT Auxiliary tank vents to the main tank via a pipe that has to run under the foot boards. Because this pipe gets lower than the tank level it can become full of fuel and so the auxiliary tank will not vent. To prevent this a limited flow ONE WAY VALVE allows any fuel to be sucked out. A large diameter BALANCE PIPE lets petrol flow between the two tanks. A smaller diameter pipe passes through the PETROL PUMP which pumps petrol from the auxiliary tank to the main tank. Petrol PUMP is driven by the vacuum/pressure pulses from the crank case. Note that the BALANCE PIPE stands up into the main tank so once the fuel level reaches that point the pump will drain the auxiliary tank and all the remaining fuel will be in the main tank. Because of this layout the fuel gauge does not drop at a steady linear rate. If you start with a full tank, fuel is used in the following three phases: 1. Fuel used from main and auxiliary tanks equally - Gauge will drop from full to ¼ . 2. Level remains constant in main tank while auxiliary is drained - Gauge remains at ¼ . 3. Fuel is used only from main tank - Gauge drops from ¼ to empty. VACUUM TAP is operated by vacuum from the inlet manifold. 6 - 1 1 of 2
Transcript
16/10/2003Piaggio Ltd. Piaggio Ltd.
TYPHOON 80 - 125 FUEL SYSTEM
Pump driven by crankcase depression
PumpOne wayvalve
Auxiliary tank vent
Balance pipe
Front tank Main tank
Vacuumtap
Supply tocarburettor
Ventcontrolvalve
Vent toatmosphere
Typhoon 80 and 125 have an auxiliary fuel tank located under the front panel. Theplumbing for this fuel system looks complicated. The Typhoon parts catalogue contains aillustration which should help you locate the components on the vehicle. The diagramabove is intended to help explain the operation of the system and should prove useful whenfault finding.VENT TO ATMOSPHERE The system has only one vent which you will find exiting underthe rear mudguard.VENT CONTROL VALVE Controls venting to prevent loss of fuel from full tank. Air canenter the tank without restriction but a slight pressure is required before vapour can exit.AUX TANK VENT Auxiliary tank vents to the main tank via a pipe that has to run under thefoot boards. Because this pipe gets lower than the tank level it can become full of fuel andso the auxiliary tank will not vent. To prevent this a limited flow ONE WAY VALVE allowsany fuel to be sucked out.A large diameter BALANCE PIPE lets petrol flow between the two tanks.A smaller diameter pipe passes through the PETROL PUMP which pumps petrol from theauxiliary tank to the main tank.Petrol PUMP is driven by the vacuum/pressure pulses from the crank case.Note that the BALANCE PIPE stands up into the main tank so once the fuel level reachesthat point the pump will drain the auxiliary tank and all the remaining fuel will be in the maintank. Because of this layout the fuel gauge does not drop at a steady linear rate. If you startwith a full tank, fuel is used in the following three phases:1. Fuel used from main and auxiliary tanks equally - Gauge will drop from full to ¼ .2. Level remains constant in main tank while auxiliary is drained - Gauge remains at ¼ .3. Fuel is used only from main tank - Gauge drops from ¼ to empty.VACUUM TAP is operated by vacuum from the inlet manifold.
6 - 11 of 2
16/10/2003Piaggio Ltd. Piaggio Ltd.
TYPHOON 80 - 125 FUEL SYSTEM
If you suspect that the fault is due to lack of fuel. Firstly prove that the carburettor isrunning out of fuel.Attach a piece of clear tube to the float bowl drain and turn it up the side of thecarburettor.Open the drain screw. you will now be able to view the fuel level. It should remain about3.5mm below the float bowl joint. If you find it is low or it drops during running then youshould explore the fuel supply.
If you have a problem that suggests a poor supply of fuel to the carburettor.1. Check that you have fuel in the main tank. If you have fuel then you can forget about the front tank and its associated plumbing, this can not affect the supply to the carburettor.
Not able to get 7 litres of fuel in scooter with a nearly empty tank. Auxiliary tank is not being used for some reason.1. Check pump. With engine running you should see the pumped fuel coming out of the pipe in the main tank.2. Check for pinched pipes particularly under foot boards and helmet compartment.3. Check auxiliary tank vent is clear of fuel (one way valve not working).
Scooter cuts out probably through lack of fuel.1. Check vent pipe is clear. Blow through it with filler cap removed.2. In the vent pipe you will find a grey and orange valve. This is a flow control valve. It should offer no resistance to air entering the tank and some resistance should be felt if you blow through it from the tank side. Do not drill a hole in the filler cap to cure a venting problem.
Fuel comes out of vent when scooter is parked in sun or on a slope.1. Vent pipe valve is faulty.2. Early 80's did not have this valve, a modification kit is available from Piaggio.
Scooter runs ok on bench but customer says it cuts out when ridden.1. Pipe trapped under helmet compartment is squashed by weight of rider.
FAULT FINDING
6 - 12 of 2
16/10/2003Piaggio Ltd. PAGE 1 OF 2
DNA FUEL SYSTEM
Early DNA125 / 180
VACUUM FROMMANIFOLD
WHITE PLASTICFUEL PUMP
NONRETURNVALVE
FUEL FILTER
OVER RUNVALVE180 only
TANKVENT
FUEL TANK
125 / 180 NOTES:1. No vacuum tap is fitted.2. Fuel pipes are clear plastic. Vacuum pipes are black rubber.3. Pump is driven by inlet manifold vacuum. not crankcase vacuum/pressure.4. Supply to carburettor is pressurised.5. DNA 125 is the same but without the over run valve.
DNA 125 / 1802001>
VACUUM FROMMANIFOLD
WHITE PLASTICFUEL PUMP
NONRETURNVALVE
FUEL FILTER
OVER RUNVALVE180 only
TANKVENT
FUEL TANK
125 / 180 NOTES:1. Vacuum tap is fitted to main tank.2. Fuel pipes are clear plastic. Vacuum pipes are black rubber.3. Pump is driven by inlet manifold vacuum. not crankcase vacuum/pressure.4. Supply to carburettor is pressurised.5. DNA 125 is the same but without the over run valve.6. DNA 180 over run valve was deleted during early 2002
VACUUMTAP
6 - 2
See Note 6.
16/10/2003Piaggio Ltd. PAGE 2 0F 2
DNA FUEL SYSTEM
Later DNA 50
METAL BODIEDFUEL PUMP
CRANKCASEPRESSURE /VACUUM
TANKVENT
MAIN FUEL TANK
MANIFOLDVACUUM
Later 50 NOTES:1. Carburettor is pressure fed.2. Fuel pipes are clear plastic. Vacuum pipes are black rubber.3. Pump is driven by crankcase vacuum/pressure. Not manifold vacuum4. Slow running adjustment is "air bleed". Turn in to richen
VACUUM TAP
Early DNA 50HEADER TANK
VACUUM TAP
METAL BODIEDFUEL PUMP
CRANKCASEPRESSURE /VACUUM
TANKVENT
MAIN FUEL TANK
MANIFOLDVACUUM
RETURN TO TANK
Early 50 NOTES:1. Carburettor is gravity fed not pressure fed.2. Fuel pipes are clear plastic. Vacuum pipes are black rubber.3. Pump is driven by crankcase vacuum/pressure. Not manifold vacuum4. Slow running adjustment is "air bleed". Turn in to richen
6 - 2
6 - 3Piaggio ltd. August 2001
HEXAGON EXS1T fuel system.
All Hexagons have a pressurised fuel supply. The original EXS1T had a feed direct from the pump to the carburettor. Most
EXS1T Hexagons have the system shown here. The return line from the header tank to the main tank is only there to allow the
header tank to fill up. The connection in the header tank has a very small holein it so air can escape but the system pressure will be maintained. It is veryimportant that this hole is not enlarged.
If system pressure is lost the scooter will still run but the mixture will now be veryweak.
The carburettor should be fitted with a float needle seat marked #1 todenote a 1mm hole. If a seat with a larger hole is used the float will not beable to shut off the fuel. The carburettor will flood and the engine will run rich.
HEADER TANKVENTING PIPE
CRANKCASE
FILTERPUMP
CARBURETOR
HEADER TANK
MAIN TANK
6 - 41 of 3
Piaggio Ltd. 06/01/06
PUMPED FUEL SYSTEMSExplanation of differences on Piaggio and Gilera scooters
These scooters all have a carburettor and pumped fuel supply:
B 125 / 200 All have a pressurised fuel system.Pump operates from the inlet manifold vacuum.Pump is near the tank and supplies fuel directly to the carburettor via an inline fuelfilter and a non return valve.
DNA 50 2 stroke. TWO different fuel systems.EARLY VEHICLES: Do not have a pressurised fuel system.The pump operates by crankcase pressure/vacuum. It feeds fuel to a header tankthat supplies the carburettor by gravity. Normal vacuum tap in header tank operatedby vacuum from inlet manifold.The return from the header to the main tank is not restricted and fuel circulatesfreely.If the header tank is not full then a fuel supply problem must be suspected.LATER VEHICLES: Have a pressurised fuel system.The pump operates by crankcase pressure/vacuum. It feeds fuel directly to thecarburettor.A vacuum tap is fitted to the bottom of the tank. This is opened by inlet manifoldvacuum.
DNA 125 / 180 4 stroke. All have a pressurised fuel system.Pump operates from inlet manifold vacuum.Pump is attached to the bottom of the tank and supplies fuel directly to thecarburettor via an inline fuel filter and a non return valve.From late 2001 all vehicles had a vacuum tap fitted to the bottom of the tank. Thetap is connected by a “T” piece to the vacuum pipe near the fuel pump.Note that the early 180 also uses the vacuum line to supply vacuum to an over runvalve on the carburettor.
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Piaggio Ltd. 06/01/06
HEXAGON 2 stroke. All have a pressurised fuel system. Pump operates bycrankcase pressure/vacuum.EXS1T early. Pump supplies fuel directly to the carburettor.EXS1T late. Same as early system but with a header tank to ensure a head of fuelto help starting after a period. The header tank has a return pipe, the connector onthe tank has a very small hole so system pressure is maintained, it is important thishole is not enlarged.ZAPM05000 (125). Pump supplies fuel directly to the carburettor.ZAPM06000 (180). Same as 125 but with a limited flow return that controls thesupply pressure. This is a “T” piece in the carburettor supply pipe and a pipe thatreturns to the tank, there is a restrictor in that pipe to limit the return and maintainthe system pressure.Refer to the separate sheet for a more detailed explanation (Hexagon LX / LXT fuelsystem)
HEXAGON 4 stroke. All have a pressurised fuel system.GTX 125 / 180. Pump operates from inlet manifold vacuum.Fuel is pumped direct to the carburettor.GT 250. (Honda engine) Electrically operated pump that is controlled by the ECU
RUNNER 2 stroke. Do not have a pressurised fuel system.The pump operates by crankcase pressure/vacuum. It feeds fuel to a header tankthat supplies the carburettor by gravity. Normal vacuum tap in header tank, vacuumfrom inlet manifold.The return from the header to the main tank is not restricted and fuel circulatesfreely.If the header tank is not full then a fuel supply problem must be suspected.
RUNNER 4 stroke. All have a pressurised fuel system.Pump operates from inlet manifold vacuum.Pump is attached to the bottom of the tank and supplies fuel directly to thecarburettor via an inline fuel filter and a non return valve.Note that the 180 also uses the vacuum line to supply vacuum to an over run valveon the carburettor.
TYPHOON 80 & 125. Do not have pressurised feed to the carburettor.They have a second tank under the front panel to increase the capacity.Fuel is pumped from the front (auxiliary) tank into the rear (main tank). The rear tankfunctions like all conventional gravity feed systems.The system is not pressurised and fuel will circulate freely between front to reartank until the front tank is empty and the rear tank is about half full.If the pump / front tank system fails the only problem is that the scooter will have areduced fuel capacity.Refer to the separate explanation sheets for more detailed operation and faultfinding information. (Typhoon 80-125 fuel system & Typhoon 80-125 fuel systemfault finding)
6 - 43 of 3
Piaggio Ltd. 06/01/06
VESPA GT 125 / 200 All have a pressurised fuel system.Pump operates from the inlet manifold vacuum.Pump is near the tank and supplies fuel directly to the carburettor via an inline fuelfilter and a non return valve.
X9. All models have a pressurised fuel system.
X9 125. Leader Engine.Pump is operated by inlet manifold vacuum. Fuel is supplied directly to thecarburettor.
X9 250. (Honda engine)Electrically operated pump that is controlled by the ECU. Fuel is supplied directly tothe carburettor.
X9 250. Quasar Engine. Have a pressurised fuel system.Pump operates from inlet manifold vacuum.Pump is near the tank and supplies fuel directly to the carburettor via an inline fuelfilter and a non return valve.
16/10/2003Piaggio Ltd. Piaggio Ltd.
VESPA PX FUEL TAP
Viewed from above. ie Sitting on the scooter
CLOSED
OPEN
RESERVE
6 - 5
1 of 3Piaggio Ltd. 06/01/04
FITTING NEW MAIN BEARINGS TO TWO STROKE AUTO’SReplacing the main bearings is not a difficult job but it MUST be done the correctway to ensure success.The problem can be that you do not achieve the correct end float in the crank sothe bearings are being side loaded. This will cause a bearing failure within a veryshort time (200 miles max!)It is vital that the end float is checked with a dial gauge once the cases havebeen bolted together.
The following assembly procedure is the best way to do the job. It is the quickestand easiest. Also it almost guarantees correct tolerance. Please do it this way:
1. Heat the bearings in engine oil. First signs of smoke from the oil is hot enough!About 100 degrees
2. Support the crankshaft vertically. Drop one bearing onto crank. If it will not dropon (by gravity) it is not hot enough. If you have to tap it home, ONLY use apiece of tube to act on the centre race. NEVER hit the outer race. Once it is onleave it to cool.
3. Turn crank over and drop other bearing on. Leave it to cool completely.4. Position the drive side crankcase half on its side with inside facing up. Support it
on blocks of wood so the crank can be dropped in (again, just using gravity).1
2 of 3Piaggio Ltd. 06/01/04
5. Heat the case with a hot air gun, mostly heat it around the area where thebearing will fit. Don't try to hurry this. It is hot enough when the rear end of thecase is too hot to keep you hand on.
6. When it is hot enough then drop the crank / bearing in and leave it to cool. If itwill not drop in easily then the case is not hot enough yet.
7. Once it is completely cold turn the case over so the crank is hanging down andthen fit the crank removal tool 20163Y (50cc) or 20262Y (125 & 180cc) as if youwere going to press the crank back out of the case.
8. Tighten the extractor bolt as tight as you can by hand. This will push the crankout against the bearing so all the free play in the bearing has been removedand the crank is pushed out as far as it can go. Do not use a spanner to tightenthe bolt or you may move the bearing. Tightening it by hand can not move thebearing (you ain't that strong). Now put the case back on it’s blocks of wood.
3 of 3Piaggio Ltd. 06/01/04
9. Heat the other (small) case half and prepare to drop it onto the crank / case.10. Fit the cases together with liquid gasket (not silicon). Don't forget the water
pump impeller on water cooled engines. Bolt it up and leave it to cool.11. Once it is completely cold remove the special tool. Now use a dial gauge to
measure the end float. Pull the crank one way, notice the gauge reading andthen push it the other way. You MUST have 0.03 - 0.09mm free play.
12. If you have nearly got the free play try tapping each end of the crank with anylon hammer and check again.
13. If you have not got enough free play there is no point carrying on. Take it apartand do it again (I would recommend using new bearings just in case the othershave been damaged!).
The reason for establishing the end float is to ensure that there is no side load onthe bearings. Ball races do not like side load and they will fail very quickly.Checking the free play guarantees that the bearing is not side loaded and theballs can run centrally in the bearing tracks.
The benefits of this method include: We only heat each part once. No wasted time re-heating We only used gravity to fit it together. No risk of damage and it must be
together properly. The bearings have only been heated in oil. No risk of damage.
Please do not try and improvise. Make sure you have all the correct tools for thejob. They are a very good investment for time saved and stress avoided.
If you have any questions please give your Regional After Sales Manager a call.
3
Piaggio Ltd. May 2000
PX 200 / 125 “COSA” TYPE CLUTCHThe COSA type clutch is now fitted to the PX 200 & PX125.
It can replace the old type clutch as a complete assembly. p/n 433548 (200cc) p/n 288650 (125cc)
2
Plain. p/n: 237272 qty. 1Thick plate with shallow splines
On the crankshaft, behind the clutch is the oil pumpdrive gear p/n: 287038.It is important that this is fittedthe correct way round, as shown.
Wavey washer.p/n: 006982
Clutch centre & bush. p/n: 285079This is keyed to the crankshaft
GEAR
NOTECHAMFER
CRANKSHAFT
3Piaggio Ltd. August 2001
PISTONS AND SMALL END BEARINGS
Small End Bearing sizes.Small end needle roller bearings fitted to two stroke twist and go engines and PXengines are supplied in four sizes they are colour coded for identification.The end of the con rod will either be colour coded or it will be marked with aseries of lines.
Bearing colour Con rod markingCopper I
Blue IIWhite IIIGreen IIII
Parts catalogues will show four partnumbers the lowest number will bethe first in this list.
Service Station manuals specify thecon rod small end diameters so youcan determine the correct bearingsize by measurement.
Piston sizes.Piaggio use alloy or cast iron barrels on different engines. Alloy barrels can notbe re-bored and over size pistons are not available. Oversize pistons areavailable for cast iron barrels. These are listed as 1M, 2M, 3M.In addition to oversize there will be four pistons listed for all engines as “FC” orFC1, FC2 etc. These are tolerance fittings.Pistons can be matched to barrels in two ways. Either by referring to thetolerance data page near the front of the appropriate Service Station Manual orby referring to the marking on the crown of the piston and the top of the barrel.On some engines barrel and piston will both have a letter stamped into them.Both letters should match. The lowest (first) part number will be the smallest pistonand first in this list.
Piston marking SizeE FC 1F FC 2G FC 3H FC 4
Remember, if you are measuring barrel and piston you should always measure inline with the gudgeon pin because they will have worn oval. Most wear occursat right angles to the gudgeon pin.
07/08/2002Piaggio Ltd. Typhoon / Runner etc.
Up side down Forks
This design is typical for any Piaggio or Gilera modelusing up side down forks
Typhoon, Runner, SKP, Zip, Skipper ST, NRG etc.
Forks are grease filled for lubrication. The grease can be expected to work past the nylon bush so the chrome stanchion will get adirty ring round it.Damping is by a sealed hydraulic damper cartridge in the left leg. The cartridge is held at the bottom by a bolt that will be found in thebottom of the axle mounting. The top of the damper rod is held by a nut on top of the top yoke. If the seals in this unit fail you will findoil dripping from the bottom of the left leg.Some 50's did not have the damper. To check if a damper is fitted: look for the nut on top of the left leg, no nut means no damper.To separate the fork leg:1. Remove damper top nut (from left leg only).2. Remove the dust seal.3. Remove the bottom circlip.4. Pulling the stanchion hard will force the upper circlip out of the tapered groove, the circlip and bush will be pulled out.On very early forks the top circlip groove was not tapered so it will be necessary to pull the bush out to get to the circlip.To pull the bush out:1. Lubricate the bush with WD40 or similar.2. Carefully screw two small self tapping screws into the nylon bush and pull it out using two pairs of pliers.Note that there are several manufactures of these forks and although they look the same the internal components may not beinterchangeable between makes.
Damper Rod RetainingNut
Bolt retains the damperand axle support
Upper Circlip
Nylon Bush
Lower Circlip
Dust Seal
LEFT FORK LEG
Fork Leg
Tapered groove
Upper Circlip
Lower Circlip
Nylon Bush
Nylon Bush
Fork Stanchion
4
25/08/057-5
SPARK PLUGSPIAGGIO / VESPA mm NGK ChampionB 125 (Beverly) 125 four stroke 0.7-0.8 CR8 EB RG4 HCB 500 (Beverly) 500 four stroke 0.7-0.8 CR7 EKB RG6 YCCosa 125 , 150 0.6 B9 ES (BR9 ES) N2C (RN2C)Cosa 200 0.6 B7 ES (BR7 ES) N4C (RN4C)Fly 50 two stroke 0.5-0.6 RGN2CFly 125 Leader four stroke 0.8 CR9 EB RG4HCFree 50 (all versions) 0.5-0.6 BR9 ES RN2CHexagon 125 &180 two stroke (all versions) 0.5-0.6 BR9 ES RN2CHexagon GT250 & GTX 250 (Honda 4 stroke) 0.8-0.9 DPR6 EA9Hexagon GTX 125 four stroke 0.7-0.8 CR9 EB RG4 HCLiberty 50 two stroke (all versions) 0.5-0.6 BR9 ES RN2CLiberty 125 four stroke (original version) 0.7-0.8 CR9 E RG4 HCLiberty 125 Leader four stroke 0.7-0.8 CR7 EB RG6 YCLiberty 125 Leader four stroke (heavy use) 0.7-0.8 CR8 EB RG4 HCLiberty 125 RST (2004>) Leader four strokeNRG 50 water cooled (heavy use) 0.5-0.6 BR10 ES RN1CNRG 50 (air or water cooled. All versions) 0.5-0.6 BR9 ES RN2CQuartz 50 0.5-0.6 BR9 ES RN2CSfera 125 four stroke 0.5-0.6 CR9 E RG4 HCSfera 50 & Sfera 80 (all versions) 0.5-0.6 BR9 ES RN2CSkipper ST 125 four stroke (all versions) 0.7-0.8 CR9 E RG4 HCSkipper 125 two stroke (all versions) 0.6-0.7 BR9 ES RN2CVelofax 50 two stroke 0.5-0.6 BR9 ES RN2CVespa 50 Special & PK50S 0.6 B6 HS L86Vespa ET2 50 two stroke (carburettor) 0.5-0.6 BR9 ES RN2CVespa ET4 50 four stroke 0.7-0.8 CR9 E RG4 HC. RG4 PHPVespa ET4 125 four stroke (all versions) 0.7-0.8 CR9 E RG4 HCVespa LX 50 four stroke 0.7-0.8 CR8EBVespa LX 50 two stroke 0.6-0.7 RGN2CVespa LX 125 four stroke 0.7-0.8 CR7EB RG6YCVespa GT 125 0.7-0.8 CR8 EB RG4 HCVespa GT 200 0.7-0.8 CR7 EB RG6 YCVespa GTS 250 injection 0.7-0.8 RG4 PHPVespa Primavera ET3 0.6 B7 HSVespa Primavera & PK 125 0.6 B6 HSVespa PX 125 0.5-0.6 B7 HS L82CVespa PX 200 0.5-0.6 B7 ES (BR7 ES) N4C (RN4C)Vespa T5 Classic 125 0.6 B9ES (BR9 ES) N2C (RN2C)X9 125 (Piaggio 4 stroke engine) 0.7-0.8 CR8 EB RG4 HCX9 250 evolution (Piaggio 4 stroke engine with carburettor) 0.7-0.8 CR8 EB RG4 HCX9 250 (Honda 4 stroke engine) 0.8-0.9 DPR7 EA9X9 500 (Piaggio 4 stroke engine) 0.7-0.8 CR7 EKB RG6 YCZip 50 four stroke 0.7-0.8 CR9 E RG4 HC. RG4 PHPZip 50 2 stroke (all versions, inc. catalytic) 0.6-0.7 BR9 ES RN2CZip 125 four stroke 0.7-0.8 CR7 EB RG6 YCGILERACoguar 125 (Honda 4 stroke engine) 0.8-0.9 DPR8 EA9DNA 125 & DNA 180 four stroke 0.7-0.8 CR8 EBDNA 50 two stroke (catalytic) 0.6-0.7 BR9 ES RN2CH@K & GSM 50 2 stroke (Gilera engine) 0.5-0.6 BR9 ES RN2CH@K & GSM 50 2 stroke (Derbi engine) 0.-0.ICE 50 two stroke catalytic 0.6-0.7 BR9 ES RN2CNexus 500 four stroke 0.7-0.8 CR7 EKB RC6 YCRCR 50 2 stroke (Derbi engine) 0.5 B9 ES (BR9 ES) N2C (RN2C)Runner VX125 & VXR180 four stroke 0.7-0.8 CR8 EBRunner VXR 200 four stroke 0.7-0.8 CR7 EKB RG6 YCRunner 50, 125 & 180 two stroke (all versions) 0.6-0.7 BR9 ES RN2CRunner 50 “Purejet” direct injection 2 stroke 0.6-0.7 RG6 YCAStalker & SKP 50 two stroke 0.5-0.6 BR9 ES RN2COLDER GILERA MOTORCYCLESSaturno 350 / 500 four stroke 0.6-0.7 DPR8 EA9 A5YCDakota 350 / 500 four stroke 0.6-0.7 DPR8 EA9 A5YCNordwest 600 four stroke 0.6-0.7 DPR9 EA9RC 600 four stroke 0.6-0.7 DPR8 EA9CX 125 & Apache & Crono & Free-Style 125 cc two stroke 0.6-0.7 B10 EG - BR9 EG N82 - C55GFR 125 two stroke 0.6-0.7 B10 EGV C55C
7-6 Oil list.xlsMake/Model Engine Gearbox Final Drive Forks Coolant
Vespa ET2 50 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 75cc sealed unit - Air -Vespa ET4 50 4 str. 5W-40 synthetic API SJ or higher 850cc CVT - Gear 80W-90 light gear GL3 or higher 80cc sealed unit - Air -Vespa LX 50 4t 4 str. 5W-40 synthetic API SJ or higher 850cc CVT - Gear 80W-90 light gear GL3 or higher 85cc sealed unit - Air -Vespa ET4 125 4 str. 20W-50 synthetic API SG or higher 850cc CVT - Gear 80W-90 light gear GL3 or higher 90cc sealed unit - Air -Vespa LX 125 & ET4 125 Leader 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 100cc sealed unit - Air -Vespa GT 125 & GT 200 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 150cc sealed unit - Ethelyne Glycol Cuna NC 956-16 2.1 - 2.5Vespa GTS 250 injection 4 str. 5W-40 synthetic API SJ or higher 1.3 ltr. CVT - Gear 75W-80 light gear GL4 or higher 250cc sealed unit - Ethelyne Glycol Cuna NC 956-16 2.1 - 2.5Vespa PX 125 / 150 / 200 2 str. Synthetic 2 stroke API TC or higher - 4 spd 80W GL4 or higher 250cc n/a - - sealed unit - Air -Piaggio B 125 & B 125 RST 4 str. 5W-40 synthetic API SJ or higher 1.1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 250cc 10W 102cc Ethelyne Glycol Cuna NC 956-16Piaggio B 500 4 str. 5W-40 synthetic API SJ or higher 1.7 ltr. CVT - Gear 80W-90 light gear GL3 or higher 250cc 10W 233cc Ethelyne Glycol Cuna NC 956-16 1.7 ltr.Piaggio Deisis 100 2 str. Hi Scooter 2 Tech - CVT - Gear 80W-90 light gear GL3 or higher 110cc sealed unit - Air -Piaggio Fly 50 2 str. Synthetic 2 stroke API TC++ or higher 1.2 ltr. CVT - Gear 80W-90 light gear GL3 or higher 85cc 20W 30cc Air -Piaggio Fly 125 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 200cc 20W 30cc Air -Piaggio Hexagon 125 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 85cc sealed unit - Ethelyne Glycol Cuna NC 956-16Piaggio Hexagon LX125 / LXT180 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 80cc sealed unit - Ethelyne Glycol Cuna NC 956-16Piaggio Hexagon GT 250 4 str. 20W-50 synthetic API SG or higher 800cc CVT - Gear 80W-90 light gear GL3 or higher 150cc sealed unit - Ethelyne Glycol Cuna NC 956-16 1.82 ltr.Piaggio Hexagon GTX 125 / 180 (11") 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 150cc sealed unit - Ethelyne Glycol Cuna NC 956-16Piaggio Hexagon GTX 125 / 180 (12") 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 150cc 10W 102cc Ethelyne Glycol Cuna NC 956-16Piaggio Liberty 50 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 100cc 20W 30cc Air -Piaggio Liberty 125 4 str. 20W-50 synthetic API SG or higher 850cc CVT - Gear 80W-90 light gear GL3 or higher 95cc 20W 90cc Air -Piaggio Liberty 125 Leader 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 200cc 20W 90cc Air -Piaggio NRG 50 water cooled models 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 85cc sealed unit - Ethelyne Glycol Cuna NC 956-16 900ccPiaggio NRG 50 air cooled models 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 85cc sealed unit - Air -Piaggio Sfera 50 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 85cc sealed unit - Air -Piaggio Sfera 125 4 str. 20W-50 synthetic API SG or higher 850cc CVT - Gear 80W-90 light gear GL3 or higher 90cc sealed unit - Air -Piaggio Skipper 125 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 80cc sealed unit - Air -Piaggio Skipper ST 125 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 150cc sealed unit - Air -Piaggio Typhoon 50 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 85cc sealed unit - Air -Piaggio Typhoon 125 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 100cc sealed unit - Air -Piaggio X8 125 / 200 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 150cc 10W 125cc Ethelyne Glycol Cuna NC 956-16 2.1 ltr.Piaggio X8 250 4 str. 5W-40 synthetic API SJ or higher 1.3 ltr. CVT - Gear 80W-90 light gear GL3 or higher 250cc 10W 133cc Ethelyne Glycol Cuna NC 956-16 2.1 ltr.Piaggio X9 125 & 125 Evolution 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 150cc 20W 90cc Ethelyne Glycol Cuna NC 956-16 1.2 ltr.Piaggio X9 250 (Honda engine) 4 str. 20W-50 synthetic API SG or higher 1.1-1.3 CVT - Gear 80W-90 light gear GL3 or higher 200cc 20W 90cc Ethelyne Glycol Cuna NC 956-16Piaggio X9 250 (Piaggio engine) 2004> 4 str. 5W-40 synthetic API SG or higher 1.3 ltr. CVT - Gear 80W-90 light gear GL3 or higher 150cc 20W 90cc Ethelyne Glycol Cuna NC 956-16 1.8 ltr.Piaggio X9 500 & 500 Evolution 4 str. 5W-40 synthetic API SJ or higher 1.7 ltr. CVT - Gear 80W-90 light gear GL3 or higher 250cc 20W 125cc Ethelyne Glycol Cuna NC 956-16 1.8 ltr.Piaggio Zip 50 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 75cc 20W 25cc Air -Piaggio Zip 50 4t 4 str. 5W-40 synthetic API SJ or higher 850cc CVT - Gear 80W-90 light gear GL3 or higher 80cc 20W 25cc Air -Piaggio Zip 125 (single sided fork) 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 100cc sealed unit - Air -Piaggio Zip 125 (telescopic fork) 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 100cc 20W 60cc Air -Gilera Coguar 125 4 str. 20W-50 synthetic API SG or higher 1.2 ltr. 5 spd. integral with engine - Chain - - 10W 280cc Air -Gilera DNA 125 / 180 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 150cc 20W 280cc Ethelyne Glycol Cuna NC 956-16Gilera DNA 50 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 100cc 20W 280cc Ethelyne Glycol Cuna NC 956-16Gilera GSM / H@K 50 (Gilera engine) 2 str. Synthetic 2 stroke API TC or higher - 6 spd. 80W GL4 or higher 500cc Chain - - 10W 200CC Ethelyne Glycol Cuna NC 956-16Gilera Ice 50 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 75cc 10W 90cc Air -Gilera Ice 50 (front fork marked "TH") 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 75cc 10W 72cc Air -Gilera RCR 50 (Paoli forks) 2 str. Synthetic 2 stroke API TC or higher - 6 spd. 80W GL4 or higher 650cc Chain - - 10W 285cc Ethelyne Glycol Cuna NC 956-16 0.85 ltr.Gilera Runner 50 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 75cc sealed unit - Ethelyne Glycol Cuna NC 956-16Gilera Runner 50 Purejet Direct injection 2 str. Synthetic 2 stroke API TC++ or higher - CVT - Gear 80W-90 light gear GL3 or higher 75cc sealed unit - Ethelyne Glycol Cuna NC 956-16 0.9 ltr.Gilera Runner FX125 / FXR180 (early) 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 80cc sealed unit - Ethelyne Glycol Cuna NC 956-16Gilera Runner FX125 / FXR180 (late) 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 80cc 20W 80cc Ethelyne Glycol Cuna NC 956-16Gilera Runner VX125 / VXR180 4 str. 5W-40 synthetic API SJ or higher 1 ltr. CVT - Gear 80W-90 light gear GL3 or higher 150cc 20W 80cc Ethelyne Glycol Cuna NC 956-16Gilera Nexus 500 4 str. 5W-40 synthetic API SJ or higher 1.7 ltr. CVT - Gear 80W-90 light gear GL3 or higher 250cc Ethelyne Glycol Cuna NC 956-16Gilera SKP (Stalker) 50 2 str. Synthetic 2 stroke API TC or higher - CVT - Gear 80W-90 light gear GL3 or higher 75cc sealed unit - Air -
Gilera GFR 125 2 str. Synthetic 2 stroke API TC or higher - 6 spd. 80W GL4 or higher 1.3 ltr. Chain - - 10W 400cc Ethelyne Glycol Cuna NC 956-16Gilera Saturno 350 / 500 4 str. 15W-40 synthetic 2.2 ltr. 5 spd. integral with engine - Chain - - ><7.5W 310cc Ethelyne Glycol Cuna NC 956-16 1.3 ltr.Gilera Nordwest 600 4 str. 15W-40 synthetic 2.2 ltr. 5 spd. integral with engine - Chain - - 10W 400cc Ethelyne Glycol Cuna NC 956-16 1.3 ltr.Gilera RC 600 4 str. 15W-40 synthetic 2.2 ltr. 5 spd. integral with engine - Chain - - 10W 640cc Ethelyne Glycol Cuna NC 956-16 1.3 ltr.
VESPA TYRES & WHEELS
MODEL FRONT REARchassis prefix wheel tyre bar wheel tyre Solo-2up
Cosa 2 125 / 200 VNR2T / VSR2T 2.50 x 10 100 / 90 - 10 T 1.5 2.50 x 10 100 / 90 - 10. T 1.75 - 2.0Vespa ET2 50 two stroke ZAPC16 / ZAPC381 2.50 x 10 100 / 80 - 10, 53L T/L 1.3 3.00 x 10 120 / 70 - 10, 54L T/L 1.8-2.0Vespa ET4 50 four stroke ZAPC26 2.50 x 10 100 / 80 - 10, 53L T/L 1.3 3.00 x 10 120 / 70 - 10, 54L T/L 1.8-2.0Vespa ET4 125 four stroke ZAPM04 2.50 x 10 100 / 80 - 10, 53L T/L 1.3 2.50 x 10 130 / 70 - 10, 62L T/L 1.8-2.0Vespa ET4 Leader 125cc four stroke ZAPM19 2.50 x 10 100 / 80 - 10, 53L T/L 1.3 3.00 x 10 120 / 70 - 10, 54L T/L 1.8-2.0Vespa LX 50 2T ZAPC38101 2.50 x 11 110 / 70 - 11, 45L T/L 1.4 3.00 x 10 120 / 70 - 10, 54L T/L 2.0Vespa LX 50 4T ZAPC383 2.50 x 11 110 / 70 - 11, 45L T/L 1.4 3.00 x 10 120 / 70 - 10, 54L T/L 2.0Vespa LX 125 ZAPM441 2.50 x 11 110 / 70 - 11, 45L T/L 1.6 3.00 x 10 120 / 70 - 10, 54L T/L 2.2Vespa PX 125 VNX2T or ZAPM093 2.10 x 10 3.50 - 10, 51J T 1.25 2.10 x 10 3.50 - 10, 51J T 1.75-2.3Vespa PX 150 ZAPM09401 2.10 x 10 3.50 - 10, 51J T 1.25 2.10 x 10 3.50 - 10, 51J T 1.75-2.3Vespa PX 200 VSX1T or ZAPM18 2.10 x 10 3.50 - 10, 59J T 1.25 2.10 x 10 3.50 - 10, 59J T 1.75-2.3Vespa GT 125 / 200 four stroke ZAPM311 / ZAPM312 3.00 x 12 120 / 70 - 12, 51P T/L 1.8 3.00 x 12 130 / 70 - 12, 62P T/L 2.2Vespa GTS 250 ZAPM451 3.00 x 12 120 / 70 - 12, 51P T/L 1.8 3.00 x 12 130 / 70 - 12, 62P T/L 2.2Vespa T5 Classic VNX5T 2.10 x 10 3.50 - 10, 59J T 1.25 2.10 x 10 3.50 - 10, 59J T 1.75 - 2.3
Bold type denotes a current model. This list was last updated on 01 February 2006. Identify a vehicle by its chassis prefix AND model name.
MODEL FRONT REARchassis prefix wheel tyre bar wheel tyre solo-2up
Coguar 125 custom ZAPM17 2.50 x 17 100 / 80 - 17, 52 S T 1.8 3.00 x 17 130 / 70 - 17, 62 T T 2.0-2.2DNA 125 / 180 four stroke ZAPM26 3.50 x 14 120 / 70 - 14, 55 P T/L 2.0 3.50 x 14 140 / 60 - 14, 64 P T/L 2.2– 2.5DNA 50 ZAPC27 3.50 x 14 120 / 70 - 14, 55 L T/L 1.8 3.50 x 14 140 / 70 - 14, 62 T/L 2.0DNA 50 RST ZAPC27 3.00 x 15 120 / 70 - 15, L or 56P T/L 1.8 3.50 x 14 140 / 70 - 14, 62L or 68P T/L 2.0GSM 50 super motard VTBC08 2.50 x 17 110 / 80 - 17, 52 T T 1.4 3.50 x 17 130 / 70 - 17, 62 T T 1.6H@K 50 trail bike VTBC08 1.40 x 21 80 / 90 - 21, 48 P T 1.4 1.85 x 18 110 / 80 - 18, 58 P T 1.6Nexus 500 ZAPM35 3.50 x 15 120 / 70 - 15, 56 H T/L 2.2 4.50 x 14 160 / 60 - 14, 65H T/L 2.5Ice 50 ZAPC30 3.00 x 10 120 / 90 - 10, 56 J T/L 1.3 3.00 x 10 120 / 90 - 10, 56 J T/l 1.8RCR 50 trail bike VTHSDR1EB 1.60 x 21 80 / 90 - 21, 48 P T 1.0-1.1 2.15 x 18 110 / 80 - 18, 58P T 1.2-1.3Runner 50 ZAPC14 / ZAPC362 3.50 x 12 120 / 70 - 12, 51L (or J) T/L 1.6 3.50 x 12 130 / 70 - 12, 56L (or J) T/L 1.8Runner 50 Purejet ZAPC361 3.50 x 12 120 / 70 - 12, 51L (or J) T/L 1.6 3.50 x 12 130 / 70 - 12, 56L (or J) T/L 1.8Runner 50 RST & Purejet RST ZAPC461 / 462 3.00 x 14 120 / 70 - 14, 55L T/L 1,7 3.50 x 13 140 x 60 - 13, 57L T/L 2.10Runner FX125 / FXR180 (rear drum) ZAPM07 / ZAPM08 3.50 x 12 120 / 70 - 12, 51L (or J) T/L 1.4 3.50 x 12 130 / 70 - 12, 56 L T/L 1.6-2.2Runner FX125 / FXR180 DD ZAPM07 / ZAPM08 3.50 x 12 120 / 70 - 12, 51L (or J) T/L 1.4 3.50 x 13 130/60-13, 60 P T/L 1.6-2.2Runner VX125 / VXR180 ZAPM24 3.50 x 12 120 / 70 - 12, 51 L T/L 1.4 3.50 x 12 130 / 70 - 12, 56 L T/L 1.6-2.2Runner VX 125 rst ZAPM461 3.00 x 14 120 / 70 - 14, 55P T/L 1.8 3.50 x 14 140 / 60 - 13, 63P T/L 2.2Runner VXR200 ZAPM24 3.50 x 12 120 / 70 - 12, 51 P T/L 1.4 3.50 x 12 130 / 70 - 12, 56 P T/L 1.6-2.2SMT 50 super motard VTHSDR1FB 110 / 80 - 17 T 1.7-1.8 130 / 70 - 17 2.0-2.1Stalker 50 (previously SKP) ZAPC13 / ZAPC401 3.50 x 10 120 / 90 - 10, 56 J T/L 1.2 3.50 x 10 130 / 90 - 10, 61 J T/L 1.6-2.0
Below are older motorcyclesGFR 125 race replica 167 3.00 x 17 110 / 70 - 17, 54 T T/L 1.8 4.00 x 17 150 / 60 - 17, 65 T T/L 2.0-2.2Nordwest 600 super motard 228 3.50 x 17 120 / 70 - 17, 60 R T/L 2.1 4.50 x 17 160 / 60 - 17, 60 R T/L 2.3-2.4RC 600 trail 228 1.85 x 21 90 / 90 - 21, 54 T T 1.8 2.50 x 17 130 / 80 - 17, 65 T T 2.0-2.2Saturno 350 & 500 café racer 222 3.00 x 17 110 / 70 - 17, 53 H T/L 2.1 4.00 x 17 160 / 60 - 17, 68 H T/L 2.3XRT 350 / 600 trail 224 / 218 1.85 x 21 90 / 90 - 21, 54 T T 1.8 2.50 x 17 130 / 80 - 17, 65 T T 2.0-2.2Chrono 125 race replica 164 2.50 x 16 100 / 80 ZR 16 T/L 1.8-2.0 3.00 x 17 130 / 70 ZR 17 T/L 2.0-2.2Apache 125 trail 1.85 x 21 90 / 90 - 21, 54 R T 1.8 2.50 x 18 120 / 80 - 18, 62 R T 2.0-2.2Freestyle 125 super motard 2.50 x 16 100 / 80 - 16, 50 S T/L 1.8-1.9 3.00 x 17 130 / 70 - 17, 62 S T/L 2.0-2.2CX 125 race replica 158 3.50 x 17 120 x 60 ZR 17 T/L 2.1-2.2 4.00 x 17 150 / 60 ZR 17 T/L 2.3-2.4
Bold type denotes a current model. This list was last updated on 13 December 2005. Identify a vehicle by its chassis prefix AND model name.
7-8
9Piaggio Ltd. 04/11/02
GILERA KEYSThe following photograph shows the different types of keys used on the recentGilera models.
Only the Runner VX / VXR has an immobiliser. Note the symbol on the key thatdenotes an immobiliser chip is fitted.
Later Runner FX / FXR keys look the same as the VX / VXR key but they do not havean immobiliser chip and the symbol is not on the key.
KEY PART NUMBERS
DNA 50 / 125 / 180 = 970239
Runner VX / VXR = 576232 with immobiliser chip
Runner FX / FXR = the shape shown in the picture is 563585 this has beensuperseded to 576719 this looks like the VXR key but does not have an immobiliserchip.
SKP 50 = 574690
ICE 50 = 576719
7-14Piaggio Ltd. 27/01/06
SERVICE LIMITSNEW LIMIT Or change at:
50cc 2T(Inc. Purejet) Belt - 17.5mm 15,000 km
Rollers - 18.5mm -Oil Pump Belt - - 20,000 kmFuel Filter - - 10,000 km (Purejet)
Restriction NotesNever discuss the technicalities of how to de-restrict with end users.
Piaggio have never supplied any information about how vehicles are restricted or how to makethem go faster.
Piaggio can not advocate de-restriction for any reason. Vehicles will only have been homologated as Mopeds so will be technically illegal if they are
de-restricted. Piaggio have never offered any tuning parts. If a 50 is de-restricted the licensing requirements will be the same as a 125, so Piaggio’s official
line is “Do not de-restrict, if you want to go faster get a 125”125cc engines are not restricted, they are designed to produce no more than 11 kw. So they will belearner legal.50cc engines are always restricted and are only sold as 45 km/h mopeds. There is no “full power”option. Most countries in Europe have the same 45 km/h category.
Restriction of 50cc 2 stroke twist and go engines.Non catalysed engines.All engines will have:
A spacer between the front pulley halves. (stops it obtaining the highest top gear ratio) A branch pipe on the exhaust. (stops the engine revving beyond a certain point)
In addition, water cooled engines will have:Older engines, starting with the first Runner and NRG MC2.
Have a tube spot welded into the inlet end of the silencer.Newer engines.
Have a tube seam welded into the out let end of the exhaust pipe.All these restrictions can be removed without the need to re-jet the carburettor.
Catalysed engines. Have the spacer and the branch pipe. These engines will need a larger main jet, four sizes up on
standard. Piaggio do not supply larger jets. Do not remove the brass baffle plate from the carburettor bell mouth if one is fitted. It is worth blanking off the “secondary air pipe” going to the exhaust just to ensure reliability.
Restriction of 50cc 4 stroke twist and go engines. See Chapter 3 page 11All engines:
A spacer between the front pulley halves. An electrical restriction in the CDI unit. They will need a larger main jet if de-restricted. Fowlers can supply this.
Restriction of 50cc 2 stroke geared engines. H@K & GSM. See Chapter 4 page 2 Only restriction is a restrictor in the inlet end of the exhaust pipe. A two size larger main jet will be needed. A standard DellOrto part.
Restriction of 50cc 2 stroke geared engines. RCR. See Chapter 4 page 9. Only restriction is a tube in the inlet end of the exhaust pipe. Increase main jet by at least four sizes. Raise needle one notch.
If de-restriction is carried out by an authorised dealer, Piaggio are happy that the warranty will notbe affected. Any tuning or fitting of after market parts by the end user or the dealer will affect thewarranty.
7 - 112 of 2
50cc Moped restriction informationWhat is a moped?A Moped is a two wheel vehicle of no more than 50cc with a design top speed of 45 km/h (28 mph)All current Piaggio, Vespa and Gilera 50cc two-wheel vehicles are restricted and are only suppliedas Moped’s. They are only tested and homologated as mopeds.Piaggio do not recommend de-restricting or modifying for any reason.If the vehicle may be used on a public road. The person carrying out the modification must take fullresponsibility for the possible implications of their actions.
If a Moped is de-restricted.
1. It becomes a 50cc Motorcycle.DVLA should be informed and the vehicle re-registered.
2. It may not conform to motorcycle requirements and may not be legal.For example; Lighting requirements are different for Mopeds and Motorcycles.Piaggio can not give any assurance that a de-restricted vehicle will be technically legal.
3. A motorcycle licence will be required.A 50cc motorcycle has the same licence requirement as a 125cc.A Motorcycle can not be ridden on a provisional motorcycle licence before basic training iscompleted (CBT).A full car licence allows a moped to be ridden but not a 50cc motorcycle.
4. A rider must be at least 17 years old.A 16 year old can ride a Moped but not a 50cc Motorcycle.
5. The Insurance company who are insuring the vehicle should be informed.The premium will probably be un-affected but any modification should be notified to theinsurer in writing. Insurance will be invalid if the vehicle is modified and the insurer notinformed.Remember that if the vehicle or the rider is not legal then the insurance will be invalid.
6. Piaggio Ltd. Are happy that the warranty will remain valid if the de-restriction is carried out byan authorised dealer.If any “tuning” or fitting of non Piaggio parts is carried out then the warranty will be invalid.
Piaggio’s advice has to be: If you want to go faster, get a 125.
Recently a 16 year old was stopped for speeding, when the Police realised his age they immediatelycharged him with.1. Exceeding the speed limit.2. Riding a motorcycle with no motorcycle licence (he was under age).3. Riding a motorcycle without valid insurance (insurance is invalid because he is riding illegally).The dealer who did the de-restriction was charged and found guilty of aiding and abetting!The boy’s father attempted to sue the dealer!A disclaimer may be of little use as a defence. Be warned! If someone rides to your shop and asksyou to de-restrict then rides away they will be breaking the law and they have only been able tobreak the law because you helped them.If you get a disclaimer signed one of the conditions should be “I do not intend to use this vehicle onpublic roads” and another should be “I am fully aware of the legal implications of having myvehicle de-restricted and I am prepared to take full responsibility for this”.
7-12Piaggio Ltd. February 2006
PIAGGIO / VESPA / GILERACHASSIS NUMBER LOCATION.
Traditional Vespa. PX 125 / 150 / 200. T5 Classic. Etc. Lift the seat. Remove engine cover (off side) by turning the off side lever near the seat
hinge, outwards. Chassis number is stamped into the chassis near the rear.
Vespa ET4, ET2, GT 125 / 200, GTS 250, Vespa LX. Lift seat. Lift out helmet storage compartment. Chassis number is stamped into the
frame across the scooter just in front of the battery.
Hexagon 125, 180 & 250. Remove seat by unscrewing the knob in the boot. Chassis number is stamped into the
frame toward the rear.
Fly 50 / 125, NRG, Skipper, Sfera, Typhoon, Zip. Gilera Runner & SKP (Stalker). Chassis number is stamped into a plate on the off side below the foot boards. You do
not need to remove anything, just look under the scooter.
Ice 50 Remove the black central cover over the oil tank filler. The Chassis number is stamped
into the main chassis tube on the off side just below the oil filler cap.
Liberty, Free Chassis number is stamped onto a plate attached to the frame on the off side above
the cooling fan cover.
Velofax Chassis number is stamped into the underside of the rear carrier (part of the frame).
X9 125, 180, 250 & 500. B 125, 200 & 500. Nexus 500, X8 125 / 250. Lift seat. Pull up the internal carpet at the rear. Remove the small panel in the floor
toward the rear. Chassis number is directly below.
DNA, H@K, GSM, RCR, Coguar and older Gilera motorcycles, Nordwest, GFR etc. The chassis number is stamped into the right hand side (off side) of the head stock.
Diesis 50, 100 The chassis number is stamped into the right hand side frame tube, underside near the
rear of the scooter and beside the frame cross tube.
A duplicate of the chassis number will not be found in any other location. If the number hasbeen removed it will not be possible to identify the vehicle.
7-131 of 4 Piaggio Ltd. 27/01/06
QUICK REFERENCE GUIDEFIRST SERVICE is always at 1000 km (625 miles)If details here contradict the Service Station Manual you should trust this information.
125 4t. (Original) air cooledCheck oil level by sight glass.Engine Oil: 10w40 synthetic. 850 cc.Oil Change: 3000 kmService: 6000 km.Rear Hub: 80w Light Gear. 90 cc.Fuel: Min 95. Unleaded.Tappets: 0.15 mm.Ign. Timing: 10° @ 1500. 32° @ 6000 rpm.Idle: 1600 – 1800 rpmSlow running: 3.5 turns out. (out to richen)CO: 3.5% (hose on exhaust outlet)Spark Plug: 0.7 - 0.8 mm
Champion RG4HCNGK CR8E (colder)
Rollers wear limit: 18.5 mm min. dia.Belt wear limit: 17.2mm (min width)Change Belt: 10,000 km (24 mths)
50/50 with distilled waterTappets: Back off one divisionIgn. Timing: 12° @ 1500. 27° @ 7000 rpmIdle: 1500 rpm.Slow running: 2 ¾ turns out (out to richen)CO: not quotedSpark Plug: 0.8 - 0.9mm
Rollers wear limit: 24.5 mm min.dia.Belt wear limit: 25 mm width.Belt Change: 12,000 km or 24 mth.Air Filter Change: 18,000 km or 36 mth.Fuel Filter Change: 48,000 km
Rollers wear limit: 20 mm min.dia.Belt wear limit: 19.5 mm min width.Belt Change: 15,000 km.Air Filter clean: 10,000 km
If there is ever any doubt about service intervals for a vehicle, always use the intervals shown inthe owners handbook.
Piaggio recommend fully synthetic oil for all engine applications. Older engines used variator rollers that needed greasing. Later greaseless rollers can be fitted to
early variators. If greased rollers are used lubricate sparingly at every service (except first): Useonly “Jota” grease p.n. 494643
Piaggio have never offered any tuning parts for any vehicles and we will never recommendtuning or de-restricting a vehicle for any reason.
All 50cc vehicles are only available as “mopeds” restricted to 45 kmh (28mph). All current 125cc vehicles are “Learner Legal” producing less than 15 hp (11kw). They are not
restricted. If they are tuned they will not be learner legal and warranty will be affected.
10Piaggio Ltd. 04/11/02
KEYS.All Leader engined vehicles with immobilisers
Notes: Only the Service key should be used day to day. The Master key should be kept
safely at home. Use the Service key for testing and fault finding. Only use the Master key for
programming. It is not possible to programme a replacement master key to a previously
programmed immobiliser. It is possible to programme new Service keys only if you have the original Master
key. Original Service keys with a chip fitted can be recognised by this symbol
etched into the metal near the top.
If new locks are fitted: Lock set will be supplied with one Master and one Service key. If you do not have any original keys then you must also change the CDI /
Immobliser unit. If you have the original Master key:
Use a screwdriver to pries the Master key apart so the Chip can be removed.Remove the chip from the new key and replace it with the original. Now theimmobiliser will not know that anything has changed.Now the system is working and you can programme the new Service keys.
Programming new Service keys:Programming is easy but be aware that precise timing can be important.
1.Master key in and turn on for TWO seconds 2. Service key in and turn on for TWO seconds 3. If you have a second Service key : In and turn on for TWO seconds 4. Master key in and turn on for TWO seconds You have up to ten seconds to change keys over. If you are adding an extra Service key you must re-programme all the Service
keys together, you can not just add a key. The system can remember up to seven keys at a time. If you programme an
eighth key then the first one will be forgotten.
Obtaining spare keys from an automotive lock smith:The system we use is also used by a lot of cars. Most automotive locksmiths will beable to supply spare Service keys. They can not supply new Master keys.
Give the locksmith the Master or Service key. They should have a suitable blank to cut. They will scan the key to identify the chip type fitted. They fit the appropriate chip to the new key. This chip will be a clone of the original so, programming will not be necessary.
Keys Galore – London – 020 7586 9741Express Keys – Kent – 01689 850008
First Access – Herts - 0115 967 6466Auto Keys – London – 020 7586 9741
